Assembly Instructions
Tools Needed:
- Adjustable wrench
- Phillips screwdriver
- Flathead screwdriver
- Pliers
- Socket set
- Torque wrench
Step-by-Step Assembly
- Unpack Components: Remove all parts from packaging and verify against parts list. Check for shipping damage.
- Handle Assembly: Attach upper and lower handle sections using provided bolts and hardware. Tighten securely.
- Deck Installation: Mount cutting deck to chassis using pivot pins and retaining clips. Ensure proper alignment.
- Wheel Assembly: Install all four wheels with axle bolts. Torque to 18-20 ft-lbs.
- Control Cable Routing: Route drive and blade control cables through designated guides. Connect to control levers.
- Battery Installation: For electric start models, install battery and connect terminals (red to positive, black to negative).
- Final Adjustments: Adjust control cables for proper engagement. Check all fasteners for tightness.
- Initial Operation Check: Add oil and fuel (if applicable). Start engine and test all functions.
Specifications
| Model Series | 20384 / 20385 / 20386 |
| Type | Self-Propelled Lawn Mower |
| Cutting Width | 22 inches |
| Drive System | All Wheel Drive (AWD) |
| Engine Type | Toro Recycler® 163cc OHV |
| Starting System | Recoil / Electric Start (model dependent) |
| Cutting Height Range | 1.5 - 4 inches (12 positions) |
| Fuel Capacity | 0.95 gallons |
| Oil Capacity | 20 oz (0.6 liters) |
| Weight | 85 lbs (38.5 kg) |
| Wheel Size | 10-inch rear / 8-inch front |
| Mulching System | Toro Recycler® 3-in-1 |
Warranty Information
- Residential Warranty: 3 years full coverage
- Commercial Warranty: 90 days limited
- Engine Warranty: 3 years (manufacturer)
- Additional Coverage: Optional extended protection plans available
For warranty service, contact Toro Customer Service at 1-888-384-9939 or visit Toro.com
Parts Diagrams
Engine Assembly
Complete breakdown of Briggs & Stratton 163cc OHV engine components including carburetor, air filter, spark plug, and recoil starter assembly.
Deck Assembly
22-inch Recycler cutting deck with blade brake clutch system, blade adapter, mulching plug, and discharge chute components.
AWD Drive System
All Wheel Drive transmission components including drive gears, axles, wheel hubs, and control linkage for front and rear wheel engagement.
Handle & Controls
Folding handle assembly with control levers, cables, and brackets. Includes height adjustment lever and drive speed control.
Wheel & Axle
10-inch rear and 8-inch front wheels with axle assemblies, bearings, and retention hardware for all four wheels.
Fuel & Oil System
Fuel tank assembly, cap, lines, and filter components. Oil fill system with dipstick and drain components.
Common Replacement Parts
Blade Set
Part # 108-7569 - High-lift mulching blade with star center
Air Filter
Part # 92-1160 - Dual-element foam and paper filter
Spark Plug
Part # 791-122 - Champion RC12YC gap .030
Drive Belt
Part # 119-3542 - AWD drive system V-belt
Wheel Kit
Part # 131-5780 - Complete wheel and axle assembly
Control Cable
Part # 138-8282 - Drive engagement cable assembly
Maintenance
| Maintenance Task | Frequency | Procedure |
|---|---|---|
| Blade Sharpening/Replacement | Every 25 hours or season | Disconnect spark plug. Remove blade, sharpen at 30° angle, balance, and reinstall with torque to 40-45 ft-lbs |
| Oil Change | Every 50 hours or season | Run engine to warm oil. Drain completely, refill with SAE 30 detergent oil (20 oz capacity) |
| Air Filter Service | Every 25 hours | Clean foam pre-filter in soapy water, replace paper element if dirty or damaged |
| Spark Plug Replacement | Every 100 hours | Replace with Champion RC12YC, gap to .030 inch, torque to 18-22 ft-lbs |
| Drive System Inspection | Every 50 hours | Check drive belt for wear, inspect AWD gears for damage, lubricate control linkages |
| Deck Cleaning | After each use | Scrape underside of deck to remove grass buildup, wash with water when cool |
Troubleshooting Common Issues
- Engine won't start: Check fuel supply, spark plug connection, and safety interlock switches
- Poor cutting performance: Sharpen or replace blade, check engine RPM, clean deck underside
- AWD not engaging: Inspect drive belt, check control cable adjustment, examine transmission
- Excessive vibration: Check for bent blade, unbalanced blade, or loose engine mounts
- Self-propel not working: Adjust drive cable, check drive wheels for engagement, inspect transmission
- Oil leakage: Check drain plug tightness, inspect gaskets, verify proper oil level
Manual Downloads
Current Model Parts Manuals
20384
22" Recycler AWD (Recoil Start)
20385
22" Recycler AWD (Electric Start)
20386
22" Recycler AWD with Personal Pace
20387
22" Recycler AWD Commercial
Related Model Manuals
20332
22" Recycler FWD
20344
21" Recycler RWD
20369
22" TimeMaster
20391
22" Super Recycler